What a 10-Micron Aerospace Defect Taught Me About Manufacturing

How can a defect smaller than a human hair cause an aircraft system to fail?In this episode of Manufacturing Runs The World, Justin Schnor sits down with Tessa Axsom, Product Marketing Manager at Fictiv, mechanical engineer, manufacturing expert, and metallurgy enthusiast.Tessa shares her unique journey through aerospace manufacturing, metallurgy, CNC machining, product development, failure analysis, and advanced manufacturing.One of the most fascinating stories from this conversation involves a microscopic defect measuring only ten microns that affected a critical electrical contact used in an aircraft communication system. The investigation revealed how an incredibly small manufacturing issue could have enormous consequences for an entire aerospace system.This episode explores:• Metallurgy and the science of metals• Aerospace manufacturing challenges• Failure analysis and root cause investigations• Why small defects create major system failures• CNC machining and manufacturing processes• Product development and prototyping• Manufacturing innovation• Engineering careers• Mentorship in manufacturing• Why hands-on experience matters for engineers• Design for manufacturing principles• The future of advanced manufacturingABOUT THE GUESTTessa Axsom is the Product Marketing Manager at Fictiv and a mechanical engineer with experience in aerospace manufacturing, metallurgy, CNC machining, finishing processes, product development, and failure analysis.hroughout her career, she has worked on aerospace components, medical applications, manufacturing processes, and engineering investigations involving material performance and failure mechanisms.ABOUT FICTIVFictiv is a global manufacturing and supply chain technology company helping innovators accelerate product development from prototype to production.Fictiv supports customers across aerospace, robotics, medical devices, consumer products, industrial equipment, and advanced manufacturing through a global network of manufacturing partners and engineering expertise.FEATURED GUESTSTessa Axsom — Product Marketing Manager, FictivFeaturing: Rachael Brownell — Content Marketing Manager, FictivWhile Tessa leads most of the conversation, Rachael joins the discussion representing Fictiv's content and manufacturing storytelling efforts.CHAPTERS00:00 Meet Tessa Axsom00:38 Why Manufacturing Is Misunderstood01:15 Engineering, Marketing & Manufacturing02:30 Falling In Love With Metallurgy03:13 What Metallurgy Actually Is03:44 Investigating Manufacturing Failures05:20 The 10-Micron Aircraft Defect06:41 Why Tiny Defects Cause Huge Problems07:02 Working Across Aerospace, Robotics & Medical08:13 Helping Innovators Build Products09:41 From Idea To Production11:31 Why Companies Switch Manufacturing Partners12:14 How Fictiv Supports Different Industries14:00 Mentorship For Young Engineers15:00 Why Hands-On Experience MattersJoin the Manufacturing Runs The World community: https://manufacturingrunstheworld.com/join-the-community/Follow Manufacturing Runs The World:YouTube: https://www.youtube.com/@ManufacturingRunsTheWorldLinkedIn: https://www.linkedin.com/company/manufacturing-runs-the-worldFacebook: https://www.facebook.com/people/Manufacturing-Runs-The-World/61576240361119/Instagram: https://www.instagram.com/mfgrunstheworldTikTok: https://www.tiktok.com/@mfgrunstheworldA Big Thank You to our Sponsors!🔹 Ellison TechnologiesEllison Technologies empowers manufacturers with advanced CNC machines, automation, and expert support—helping shops work smarter, faster, and more competitively.👉 https://ellisontechnologies.com🔹 GSC – 3D & AutomationGSC is one of the nation’s leading resellers of SOLIDWORKS CAD software and Markforged industrial 3D printers, empowering engineers and manufacturers with cutting-edge design, simulation, and additive manufacturing solutions.👉 https://gsc-3d.com